MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
WINTER 16 EXAMINATION
Model Answer Subject Code: 17609
__________________________________________________________________________________________________
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidates answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidates understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.

Q. Sub Answer Marking

No. Q. N Scheme

1. a) Attempt any THREE of the following: 12

(i) Define production and list the types of production system.
Ans: Production:- production is any process or procedure developed to transform a set of Definition
input elements like men, materials, capital, information and energy into a specified set of 2 marks.
output elements like finished products and services in proper quantity and quality thus
achieving the objectives of an enterprise. There are four factors of production. Those are List of
as follows. production
A) Land & Natural resources system 2
B) Labour marks.
C) Capital
D) Enterprise

List of Production System:

1. Intermittent production
a. Job order production system.
b. Batch order production system.
2. Continuous production
a. Mass production system.
b. Process production.
(ii) How productivity is measured? Explain any one method of productivity measurement.

Ans: Measurement of productivity: Explanation

of
- For measurement of productivity, one must find out input and output of the productivity
system. To measure the input resources and goods or services supplied is a measurement
critical job as they are varying nature. 2 marks

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- To compare output and input, the better method is to convert both into money
terms. So in general productivity of firm can be measured from following
equation.

- Productivity =

- Thus productivity can be measured either on aggregate basis or on an individual

basis. If individual input resource is considered, the output is compared with any
one of the input resource. Some of these are given below.

- Labour Productivity: Any method

with correct
In case of labour productivity input and output can be measured in terms of ratio 2
marks.
money or in terms of man hour.
a. In terms of money,
Productivity =
b. In terms of hours,
Productivity =
- Material Productivity:
i. Material consist of direct material and indirect material, Direct material
means which goes with the product and indirect material means other
consumable like fuel, chemicals in heat treatment, cutting tools, coolant
etc. Material productivity measures in terms of goods produced.
ii. Therefore, Material Productivity =
- Machine productivity:
It is measured in terms of hours.
Machine Productivity =
- Overall Productivity:
For measuring total or overall productivity of any firm following formula is used,
Overall Productivity =

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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WINTER 16 EXAMINATION
Model Answer Subject Code: 17609
__________________________________________________________________________________________________
(iii) Explain techniques for improving productivity. Any four
techniques
Ans: Technique for improving Productivity with
a) Work Study: - Work study aims two objectives one is to find out the best method of description -4
doing job and another one is to find the time taken to do it. This is done by breaking marks.
down the job into it various elements, eliminating all unnecessary movements and
estimating the time taken to do this job with the help of stopwatch. Second aim is to
ensure that all workers engaged in the job are trained to do it in the best way.
b) Human Relations: - Good human relations help in co-oprative behavior from workers
which results in increase in productivity. Human relations can be improved by labour
participation in goal setting, simplification in communication system minimizing the
conflicts, encouragement and awarding rewards etc
c) Incentives: - When incentives schemes are introduced in a firm, it results a
considerable improvement in productivity. It is something that encouraged a worker to
put in more productivity effort. Works will not give 100% unless their interest in work is
created by some kind of reward.
d) Cost Control: - Productivity can be increased by reducing the cost of production. This
can be done by keeping careful watch over expenditure, reduction in wastage, reducing
machine breakdown time, reducing waiting time for inventory avoiding excessive
handling, minimizing overtime expenses etc.
e) Product design: - A good design of product helps in economical and convenient
manufacturing. It will also minimize wastage or scrap and reduce the cost of production.
In order to achieve high productivity, product design must be simple to understand,
standardization and simplification increases the production efficiency, research and
development contributes improvement in product design, product development reduces
ineffective time due to change in design, design must considered the current the current
available technology.
f) Working Conditions or ergonomics: - It is nothing but the design the man machine
system in such a way that to ensure high productivity and safety of workers. Working
conditions like lighting, ventilation, working hours, supervision etc definitely affects the
productivity. Also water facility, sitting room, bathroom, and toilets in sufficient
numbers are considered to maintain working conditions. To motivate workers
productivity related statement are displayed in a firm such that workers can read it
frequently.
g) Management by objectives:- It is process where the superior and subordinate
management jointly identify common goal and define individual responsibility in terms
of results expected from him
h) Total Quality Management: - By this it obtained the greater customer satisfaction,
fewer defects and less waste improved profitability and increased productivity.
(iv) Define dispatching and list any two functions of dispatching department. Definition
2 marks.
Ans: Definition of dispatching: Dispatching is the routine of starting productive activities in
motions, through release of orders in accordance with preplanned route sheets and
operations sheet. Any two
functions 2
Functions of dispatching department: marks.

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__________________________________________________________________________________________________
1. To issue work order to different departments.
2. To release material orders from stores.
3. To ensure release of correct tools, jigs and fixtures.
4. Keep a record of starting and completion date of each operation.
5. Collection of route sheet and other document from the shops.
6. Issue of inspection order of each operation.

b) Attempt any ONE of the following: 06

(i) Discuss in brief important factors to be considered while making site selection for new
industry/plant.

Ans: Factors to be considered while making site selection for new industry/plant: Any six
factors with
1. Availability of raw material: As far as possible the site selected should be near
explanation
the source of raw materials so that cost of transportation can be minimized and 06 marks.
storing cost can be reduced especially when the raw material is heavy and bulky
or cheap but looses a good amount of weight during processing. For example
most of the iron and steel industries are situated in Orissa and Bihar, Paper
industries in Ballarpur due to availability of raw material in these areas.
2. Availability of labour: Available of right kind of labour in required numbers of
reasonable rates is also deciding factor in site selection. Unskilled labours are
amply available at major industrial areas and rural areas but however firms
requiring skilled labour be situated near the urban industrial area.
3. Climatic condition: Climatic conditions largely affect certain production
processes and also the efficiency of employees. For example textile industries
required moist climate due to which these types of industries are situated near
Ahmadabad and Mumbai; similarly Tea and Coffee near Assam.
4. Proximity of market: Market is another important factor affecting site selection.
Industrial units using raw material should be located near the markets to serve the
customer with minimum service cost.
5. Transport and communication facilities: While selecting the site, adequate
transportation facilities should be considered. The optimum site is the site which
is well connected by various modes of transportation.
6. Availability of water: Water is required for drinking and sanitary purpose of all
industries. Therefore, clean and adequate water should be available near the site.
7. Availability of power and fuel: All industries require power and fuel to run the
prime movers. Therefore, the site selected should have these facilities available at
cheaper rate.
8. Legal Aspects: Local bye laws, taxes etc. are also important because they
directly reflect in total cost. So while selection, it should also consider legal
aspects.
9. Amenities and recreational facilities: Facilities like schools, hospitals, garden,
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Model Answer Subject Code: 17609
__________________________________________________________________________________________________
play grounds should also be needed for employee and their family.
10. Scope of Future expansion: Site selected should be in such a way that a plenty
of land other facilities must be available for future expansion.

Explain the concept of line balancing. State its importance and objectives.
(ii)
Concept of line balancing : Concept
Ans: 2Marks.
- Line balancing means assigning the equal work content to each work station in
the assembly line.
- For example: If a product is completed by using three different machines A, B
& C in sequence. If A can process 10 pieces / unit time, if b can process 15
pieces / unit time & if C can process 30 pieces / unit time. Then for line
balancing, 3 machines of type A, 2 machines of type B with every machine of
type C. So that constant output of 30 pieces / unit time at each work station can
be achieved.
Importance of line balancing: Any two
points or
1. By this the proper utilization of machine is taken place. proper
2. By this there is proper utilization of worker is taken place. explanation
3. The idle time for man and machine is minimum in line balancing. of
4. The production rate is more in line balancing. importance -
5. The cost of production is cheaper than other method. 2 marks.
Objectives of line balancing: Any two
points of
1. To distribute the tasks evenly at every workstation. objectives
2. To minimize the ideal time at each workstation. 2 marks.
3. To utilize all the resources in proper manner.
4. To minimize cost of production.

2. Attempt any TWO of the following: 16

a) Name different types of material handling equipments used in industry. Explain any one
with neat sketch. Classification
4 marks
Types of material handling devices
Ans:
1.Trucks : Explanation
i) Power lift : of any one
a. Fork lift device with
b. elevating platform neat sketch
ii) Hand Lift. 4 marks
iii) Porters trolley. (2 marks for
2.Tractors and trailers explanation
3. Hoist and cranes: and 2 marks
i) Hoist for sketch.)
a. Chain hoist. here one type
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b. Electric hoist. given for
ii) Crane example,
a. Over bridge crane examiner
b. Jib crane. should
4.Conveyers : consider any
a. Belt conveyer. type of
b. Roller conveyer. device.
c. Chain Conveyer.
d. Screw conveyer.
5.Automated guided vehicle
Belt Conveyer:
1. Belt conveyers are particularly suitable for package handling because of their
smooth, noiseless operation.
2. It can be used for handling of materials in horizontal or inclined direction.
3. Belt conveyer consists of an endless belt, idler roller, structure, a head pulley, a
tail pulley and suitable drive.
4. The width of belt ranges from 8 cm to 100 cm. and material of belt can be
rubber, plastic, leather, sometimes flat steel bands can also be used.
5. Speed of belt normally ranges from 1 m/s to 70 m/s.

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WINTER 16 EXAMINATION
Model Answer Subject Code: 17609
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b) State and explain the various factors affecting process planning. (Any 4 points
with
Ans: Factors affecting process planning. appropriate
explanation-8
a. Size and shape of part: The size and shape of many components decides the basic
Marks)
operations for the manufacturing of pert. For example : For manufacturing a shaft, the
necessity information is shape of raw material, size of shaft, according to that we select
the sequence of operations, machines to be used and material handling activities.
b. Strength characteristics of the part: The part strength also decides that which type
of process is employed for producing it. Because the different types of load acted on the
part during its working such as impact load, tensile load or shock load etc. according to
that process planning is done.
c. Quantity required: According to the no. of output produced, the process planning is
decided. For example: Part which is manufacture in large no. for that general purpose
machine is used and for large size and less no. of part special purpose machines are used.
d. The accuracy and surface quality required: For achieving accuracy, product should
be manufactured such a way that it should give higher dimensional accuracy and high
degree of surface finish according to that machines and process is to be selected.
e. Utilization of existing equipments: While selecting the process, full capacity of
existing machines & its tooling must be utilized, otherwise the existing machinery will
remain idle and more capital will be invested on new machines.
f. Skill of manpower: Skill of available manpower must be known to determine the need
for added operations to avoid defectives due to poor workmanship.
g. Delivery date of components or product: Short time period of delivery generally do
not allow process engineer to select most economical process and tool for economic
production. Due to insufficient time, he may use less efficient machine and tool on hand.
On other hand, longer delivery schedule give process engineer sufficient time to go
details of each aspect to select most economical process.

c) How inspection stages are determined? State the significance of operation sheet. Any four
points 4
Ans: Following points taken into considerations for determine stages of inspection.
marks.
1. Type of production system. i.e. Job, batch or mass etc.
2. Nature of product i.e. complex which consist of more number of parts or simple
one.
3. Process selected for manufacture which consist of simple or complex operations
or which consist of cheap or costly operations.
4. Type of layout i.e. line layout or functional layout etc.
5. Finding the key operations in process responsible for the essential function of the
product.
6. The cost incurred on inspection i.e. money spend on inspection and cost of
allowing defective parts per lot.

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WINTER 16 EXAMINATION
Model Answer Subject Code: 17609
__________________________________________________________________________________________________
Any four
Significance of operation sheet. points of
1. The operation sheet gives the information that is very vital to process significance
engineer.
4 marks.
2. It helps the supervisor to know which operation is being performed on the
job.
3. It helps the worker to clearly understand the drawing.
4. It also instructs the worker about the speed, feed and depth of cut to be used
for particular operation.
5. It also gives the information about the time required for the operation. This
can help the process engineer to schedule the similar jobs.
6. The information like the availability of machines can also be obtained from
the operation sheet.
7. As the operation sheet is one of the activity in the process plan, it helps to get
a systematic process plan.

3. Attempt any FOUR of the following: 12

a) State different types of plant layout. Explain any one type.

Ans: Types of plant layout. List of Types

1 mark.
There are three types of plant layout depending upon the volume of production. They are

1. Line or Product layout.

Explanation
2. Functional or Process layout. of any one
3. Project or Fixed position layout. type with
sketch 3
Line or Product layout: marks
In this type of layout, the machine and auxiliary services are arranged in line
according to sequence of operations to be performed. The raw materials enter in the
line at one end, the operations are carried out in succession in a smooth flow and
finished product is delivered at other end of the line. In this layout, there will be a
separate production line for each type of product. Product layout is suitable for
continuous production where there is a stable product demand.

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Functional or Process layout:

Process layout also known as functional layout. In this layout machine performing
similar operations are grouped together, and are not arranged according to any
particular sequence of operations. The machine group together in different
department or even different building therefore lot of cross movement of work take
place. Due to this, process layout is suitable for low volume of production & where
the product is not standardized.

Project or Fixed layout:

When the jobs are huge size and heavy, then, in such case, men and machines move

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with respect to work/job to perform the required operations. Such a layout is known
as static or fixed position layout. Such type of layout is typical in customer oriented
type production like ship building, air craft construction, large turbo generators, etc.

b) State and explain the basic principle to be followed to develop a good plant layout. Any four
points with
Ans: Following are the basic principle to be followed to develop a good plant layout. explanation
4 marks.
1. Overall integration: A good layout is one that integrates men, materials, machine
and supporting services, and others in order to get the optimum utilization of resources
and maximum effectiveness.
2. Smooth flow of product: A good layout is one that makes the material to move in
forward direction towards the completion stage, i.e., there should not be back tracking.
3. Minimum distance travelled: This means minimum movement of men and
materials. The facilities should be arranged such that, the total distance travelled by the
men and material should be minimum and as far as possible straight line movement
should be preferred.
4. Space utilization: The good layout is one that utilized both horizontal and vertical
space. It is not only enough if only the floor area is utilized optimally but the third
dimension, i.e., the height is also utilized effectively.
5. Flexibility: The good layout is that can be altered without much cost and time, i.e.,
future requirements should be taken into account while designing the present layout.
6. Minimum handling: A good layout is that which reduced the material handling to
minimum.
7. Maximum visibility: The plant should be planned in such a way that, there should not
be any difficulty in supervision, co-ordination and control. There should not be no
hiding space into which goods can be mislaid.
8. Employee satisfaction and safety: A good layout is one that gives due consideration
to workers safety and satisfaction and safeguard the plant and machinery against fire,
theft etc.

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9. Maximum accessibility: All servicing and maintenance point should be readily
accessible without making any hindrance to the production process. For this purpose
there must be sufficient space between different machines.

c) Explain in brief steps involved in process planning. Proper

explanation
Ans: Steps involved in process planning: with correct
1. Analysis of Product and its specification: - During analysis, following parameter sequence of
should be considered, steps 4
a. Drawing and specification of product. marks.
b. Quality of product.
c. Number of parts/components per product.
2. Make or buy decision: Process planning determines what parts are to be
manufactured in the firm itself and what parts are to be purchased from outside.
3. Selection of basic manufacturing process: Once the decision is taken what parts to
be manufactured, next step is to decide the manufacturing process. The alternative
methods are compared and most practical and economical method is decided by
calculating and comparing total cost for two or more feasible method.
4. Determining sequence of operation: Once the best manufacturing process is
selected, sequence of operation to be performed on each component is determined.
5. Combine the operations: If possible practically, combine as many operations as
possible. As it is economical to combine the operations.
6. Selection of machine tools/equipments: Selection of correct machine is closely
related to the process of manufacture. While selecting the machine, following factors
should be considered:
a. Size and form of work piece. b. Accuracy and surface finish required.
c. Quantity required.
7. Inspection: At this stage, inspection devices and stages are decided.
8. Requirement of tools, gauges etc.: To determine and order the tools and gauges
required to manufacture the part.
9. Labour requirement: Kind/Skill of labour required to do the job.
10. Time standards: To determine the time standards for performance of the job and
fixing the rates of payment.
11. Prepare the route sheet and operation sheet.

d) State and explain how the different operations can be combined? Two methods
with proper
Ans: Bye two methods operation can be combined. explanation
4 marks.
1. Simulation method: In this method, different operations are combined together
and performed the simultaneously in one setting. For example, straddle milling,
gang milling operation, slot making operation on CNC machine centers etc.
2. Integration Method: When a set of operations selected for a process arranged so
as to perform one after other, not simultaneously is the method of integration.
Here operations are carried out in succession without disturbing setups. For
example operations on turret lathe, multi spindle automats, CNC operations etc.

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e) What are the objectives of method study? Any four
points 4
Ans: Objectives :- marks.
1. Improvement in process and procedures.
2. To find the best way of doing job.
3. Better workplace layout and better working condition.
4. Less fatigue to operators.
5. Better product quality.
6. Improvement in the use of materials, machines and manpower.
7. Efficient and fast material handling.
8. Greater job satisfaction, higher standards of safety and health.
9. Reduction in waste and scrap.
10. Smooth and streamline flow of production and processes.

f) Differentiate between Jigs and Fixtures. Any four

points 4
Ans: Sr.No Jigs Fixtures marks.

1. Jigs holds and locate the work piece
and also guide the cutting tool to the
work.
2. Jigs are movable device and
generally not fixed to the machine
table.
3. Jigs are usually lighter in
construction than fixtures.
Fixture only holds and locates the work
piece and does not guide the tool.
Fixture are fixed device, usually
clamped or bolted to the machine table.
Fixtures are usually heavy in
construction.

4. It requires drill bushes. It requires setting block.

5. Most jigs uses standard parts such as Fixtures does not use standard
drill bushes, dwell pins etc. components.

6. Jigs are used on drilling, reaming, Fixtures are used with turning, milling,
tapping, and counter boring grinding, shaping etc.
operation.
4 a) Attempt Any Three of the Following

i) Explain any two clamping devices with neat sketch

Ans [1] Screw clamp:- It is particularly useful when a component is to be gripped on its edges.
This arrangement insures easy machining of top surface of work piece.
[2] Equalizing clamp: - It is used for exerting equal pressure on two spots of the face of
1 Mark
the work piece. It consists of clamp, legs and screws.
each for
any two
correct
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explanation

And

1 Mark
each for
any two
correct
diagram

Figure:- Screw Clamp Figure:- Equalizing Clamp

[3] Pivoted clamp:- It consist of strap and screw . It eliminates used of spanner for
clamping the work piece.
[4] ) Latch clamp:- This is special type of clamp which provide a means of entry for
loading and unloading of work piece. For this strap or latch can be swung out or in.
[5] Wedge clamp: - it consists of jig body, button, wedge and screw. It is extensively used
in jigs and fixture due its rapid action. The clamp is operated by actuating the handle,
which in turns lock and unlock the work piece.
[6] Hinged Jaw clamp:- This clamp is similar to swinging latch clamp in which the latch
is hinged to enable the work piece to be loaded and un loaded. The clamp can be made
integral with the latch
[7] Two way clamp:- It is rapid clamping device , consist of two levers by which clamping
takes place in two direction with one screw.
[8] Cam operated clamp:- These clamp find broad application and are fast and positive in
action. The clamp is operated by simply actuating the handle up or down which locks or
unlocks the strap with the work.

ii) Explain the concept of ERP

Ans Enterprise resource planning (ERP) is a business management softwareusually a suite

of integrated applicationsthat a company can use to collect, store, manage and
interpret data from many business activities, including:

Product planning, cost

Manufacturing or service delivery
Marketing and sales
Inventory management
Shipping and payment
1 Mark for
ERP came to represent a larger whole that reflects the evolution of application integration Concept
beyond manufacturing. and
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3 Marks
for
Explanation

ERP provides an integrated view of core business processes, often in real-time, using
common databases maintained by a database management system. ERP systems track
business resourcescash, raw materials, production capacityand the status of business
commitments: orders, purchase orders, and payroll.

ERP (Enterprise Resource Planning) systems typically include the following characteristics:

An integrated system that operates in (or near) real time without relying on periodic
updates.
A common database that supports all applications
A consistent look and feel across modules

iii) Explain the concept of continuous improvement

Kai = Change Zen = for the better
Ans Kaizen is a Japanese term that basically translated to continuous improvement or change to
become good is a management concept originated by the Japanese in order to continuously
effect incremental changes for the better, involving everybody within the organization from Marks
worker to managers. Kaizen is aimed at producing more & more value with less & less
waste, attaining better working environment& developing stable process by
standardization. The implementation cycle includes Planning of activities to be done.
Prepare the action plan for performing those activities after that check the possibilities of
performing those and feasibility of the same. Act according to the action plan. This cycle is
also called as PDCA cycle.
iv) Explain robot anatomy and structure with sketch
Ans Robot Anatomy:- Robot anatomy concerns with the physical construction and 2 Marks
characteristics of the body , arm , wrist which are components of the robot manipulator. for
Most robots are mounted on a base. The body is attached to the base and the arm assembly Description
to the body. At the end of arm there is a wrist & consists of various joints which provides
sliding and rotation motion. End effectors are attached to the wrist that performs the work. And
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Robot may be attached permanently to the floor, may move along overhead rails or 2 Marks
may be equipped with wheels to move on floor. for Sketch
Five common anatomies of robots are available:-
1) Rectangular 2) Cylindrical 3) Spherical 4) Jointed arm 5) SCARA

4 b) Attempt any ONE of the following

i)
Construct two handed process chart for the assembly of Nut and bolt with summary
Ans
Task :- Assembly of Nut and Bolt
Chart begins :- Both hands free before task
Chart ends :- Both hands free after task
Charted by :- -----
Date of Charting :- ------
4 Marks
Left Hand Right Hand
for Chart
Description Symbol Symbol Description
And
Nut to the workstation Bolt to the workstation
2 Marks
for
Position nut on bolt Grasp the bolt securely Summary

Thread nut Hold the bolt

Inspect Hold

To the bin Transfer assembly to left hand

Drop the assembly to bin Wait

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Symbol

Frequency ( L.H. ) 3 2 1 ---- ----

Frequency (R. H.) 2 1 ---- 2 1

ii) Explain pull and push types of manufacturing system

3 Marks
Ans Pull Type Manufacturing System:
[1] Just in Time (JIT) is a pull system which is also known as Make to Order Production.
[2] Pull System means that parts are produced to order and the production is matched with
demand for the final assembly of products.
[3] In Make to order production system, there is a direct interaction with customers during
all the stages but it is expensive during engineering phase..
Characteristics of Pull (Make to Order) Manufacturing System:
[1] Direct interaction with customers
[2] Production schedule changes with changes in customer order
[3] Capacity utilization is lower
[4] Capacity requirements planning are critical
[5] Shop floor control is critical
[6] Distribution is less complicated
Examples: Custom Tailored Clothing, Special Purpose Machinery and product made to
customer specifications
Push type system 3 Marks
It is often said that Material Requirements Planning (MRP) is a Push system. In MRP the
detailed quantity of raw material required for production is planned. It tells when each item
must be ordered and delivered so as to ensure timely delivery.

Push type" means Make to Stock in which the production is not based on actual demand.
"Push type" is represented by "Make to Stock" (MTS) in which the production is not based
on actual demand.

5 a) Attempt any FOUR of the following

Ans
Explain 3-2-1 principle of location with suitable example
[1] It is also known as six pin or six point location principle. In this, the three adjacent 2 Marks for
locating surfaces of the blank Explanation
(work piece) are resting against 3, 2 and 1 pins respectively, which prevent 9 degrees of and
freedom.
[2] The rest three degrees of freedom are arrested by three external forces usually provided 2 Marks for
directly by clamping. Sketch
The 3-2-1 principle states that the six locators are sufficient to restrict the required degree
of freedom of any work piece. In this, motion is restricted using clamps and locators. A
three pin base can restrict five motions and six pins restrict nine motions.

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Model Answer Subject Code: 17609
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b) State and explain general principle of jig and fixture design 1 Mark each
Ans Principle of jigs and fixture design: for Any 4
1. Before planning the design of a tool, compare the cost of production of the work with Points with
present tools with the expected cost of production, using the tool to be made. Confirm that explanation
the cost of building jigs & fixture is not in excess of expected gain.
2. Before lying out the jigs & fixture decide upon the location point & outline a clamping
arrangement.
3. Make all clamping & building devices as quick acting as possible.
4. In selecting the location points, see that two component part of a machine can be located
from corresponding points & surfaces.
5. Make the jig 'fool-proof' that means design it in such way that work cannot be inserted
except in the correct way.
6. For rough casting, make some of the locating points adjustable.
7. Locate clamps so that they will be in the best position to resist the pressure of cutting
tool when at work.
8. Wherever possible make all clamps, integral parts of jig or fixture.
9. Avoid complicated clamping arrangements which are liable to wear or get out of order
10. Place or clamps as nearly as possible opposite to some bearing point of the work to
avoid springing.
11. Round all corners.
c) What is mean by 5 S? Explain the meaning of each S in detail
Ans Meaning of 5S:- 2 Marks
for
5S is the name of a workplace organization methodology that uses a list of meaning
five Japanese words which are seiri, seiton, seiso, seiketsu and shitsuke constitute the
system.
Interpretation of S:-
Japanese English
Meaning
Term Equivalent

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__________________________________________________________________________________________________
SEIRI Tidiness Unrelated materials in workplace

SEITON Orderliness Set everything in proper for quick storage and retrieval
2 Marks
SEISO Cleanliness Clean the workplace, everything should be janitor for
Interpretation

SEIKETSU Standardization Standardize the way of manipulating the cleanliness

Practice 5s daily, make it a way of life this also

SHITSUKE Discipline
means a commitment

Explain spherical configuration with neat sketch

d)
Spherical Configuration
Ans 2 Marks for
These robots have a work space of spherical shape. In general, the arm is linked to the base
explanation
with a twisting (T) joint and rotatory (R) and or linear (L) joints. The designation of the
arm for this arm can be TRL or TRR. Robots with the description of TRL are also called
polar robots.
And
IT uses telescopic arm that can be raised or lowered about a horizontal pivot point. The
pivot point is mounted on a rotating base and gives the robot its vertical movement.
These various joints provide the robot with the ability to move its arm within a spherical
2 Marks for
envelope. sketch

Explain tactile sensors in robots

e)
Tactile Sensors:- 4 Marks
Ans Tactile sensors provide the robot with the capability to respond to contact forces between
itself and other objects within its work volume. Tactile sensors can be divided into two
types:
[1] Touch Sensor is used simply to indicate whether contact has been made with an object.
A simple micro switch can serve the purpose of a touch sensor.
[2] Stress Sensor is used to measure the magnitude of the contact force. Strain gauge
devices are typically employed in force measuring sensors.
f) What are grippers? Explain vacuum actuated grippers in brief
Ans Grippers:-
A gripper is a device which enables the holding of an object to be manipulated. a gripper
enables holding, tightening, handling and releasing of an object.
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Vacuum Grippers:-
The vacuum grippers also called vacuum cups or suction cups which uses vacuum as a
gripping force. The lifting and holding is done by cups or vacuum surface driven by vacuum 1 Mark
system. The Vacuum pump or venture system.
[1] Usually the cups are available in round or oval shape. The common diameter size of cups is
in between 30 mm to 200 mm. The selection of cup and number of cups required depends on:
[2] Weight of the part.
[3] Part size and shape.
[4] Nature and type of part etc.
Sometime to increase the contact area, multiple cups are used. Vacuum cups are used to lift flat 3 Marks
as well as curved surfaces.
Examples: Vacuum cup or Suction Cup, some vacuum grippers use a closed-cell foam rubber
layer for gripping application.
6 Attempt any TWO of the following
a) Explain the GANTT CHART used in production planning and control. Sate its advantages
and disadvantages
Gantt Chart is a project planning tool that can be used to represent the timing of tasks
Ans required to complete a project. Because Gantt chats are simple to understand and easy to
construct, they are used by most project managers for all but the most complex projects.
[1] In a Gantt Chart, each task takes up on row.
[2] Dates run along the top in increments of days, weeks or months, depending on the total
length of the project.
[3] The expected time for each task is represented by a horizontal bar whose left end marks 2 Marks
the expected beginning of the task and whose right end marks the expected completion for
date. explanation
[4] Tasks may run sequentially, in parallel or overlapping.
[5] Gantt charts are particularly helpful ways of dealing with scheduling tasks,
understanding critical paths of project and planning of resources

2 Marks
for
Diagram

Figure:- Gantt Chart

Advantages of Gantt chart:

[1] Gantt Chart is simple graphical display technique, suitable for less complex situations
[2] Gantt charts are extremely easy to understand. 2 Marks for

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[3] It can quickly reveal the current or planned situation to all concerned. any four
[4] It does not provide any rules for choosing but simply presents a graphical technique for Advantages
displaying results (and schedule) and for evaluating results (make span, idle time, waiting
time, machine utilization, etc.)
[5] There is clarity in communicating important shop information by using Gantt chart

Disadvantages of Gantt chart:

[1] The Gantt chart must be updated periodically to account for new jobs.
[2] It is used for communicate relatively less information.
[3] Lack of adequate depiction of interrelationship between the separate tasks.
(It means how the ability to start one task depends upon the successful completion of other
tasks.) 2 Mark for
any four
[4] Requires greater time to maintain Disadvantag
b)
es
A shop floor activity consists of three elements. Calculate the standard time for the
activity. The various allowances are given as percentage of normal time.

Elements A B C
Observed time (min) 1.25 1.2 2.85
Rating factor (%) 90 115 85
Relaxation allowance (%) 12 13 8
Delay allowance (%) 3 6 5
Personal allowance (%) 8 6 4
Ans
Elements Observed Rating Basic Time
time (Normal Time)
A 1.25 90 =1.25 X (90 / 100)
= 1.125
B 1.2 115 =1.2 X (115/100)
= 1.38 4 Marks for
C 2.85 85 =2.85 X (85 / 100) Calculating
= 2.4225 Total time

Total time = 1.125 + 1.38 + 2.42 = 4.9275 Min

1) Relaxation Allowance = (12/100 X 4.9275) + (13/100 X 4.9275) + ( 8/100 X 4.9275) 3 Marks for
Calculating
= 0.5913 + 0.6405 + 0.3942
Allowance
= 1.626 Min Time
2) Delay Allowance = ( 3/100 X 4.9275) + (6/100 X 4.9275) + ( 5/100 X 4.9275)
= 0.1478 + 0.2956 + 0.2463
= 0.6897 Min
3) Personal Allowance = (8/100 X 4.9275) + (6/100 X 4.9275) + ( 4/100 X 4.9275)
= 0.3942 + 0.2956 + 0.1971
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= 0.8869 Min 1 Mark for
Standard
Standard Time = (4.9245 + 1.626 + 0.6897 + 0.8869)
Time
= 8.1301 Min

c) What are actuators? Explain mechanical and hydraulic actuators type with
advantages and disadvantages
Ans Actuators:-
An actuator is a component of a machine that is responsible for moving or controlling a 2 Marks
mechanism or system.
Mechanical Actuator:-
A mechanical actuator functions to execute movement by converting one kind of motion, 1 Mark for
Explanation
such as rotary motion, into another kind, such as linear motion. An example is a rack and
pinion.
The operation of mechanical actuators is based on combinations of structural components,
1 Mark for
such as gears and rails, or pulleys and chains. Advantages
Advantages:-
[1] Simple in construction 1 Mark for
[2] Reliable Disadvantag
es
Disadvantages:-
[1] Slightly lower efficiency compare to other
[2] Frequent Maintenance required 1 Mark for
Hydraulic Actuator Explanation
According to Pascal, when there is an increase in pressure at any point in a confined
incompressible fluid, then there is an equal increase at every point in the container.
Hydraulic actuators are designed based on this principle (Pascals law).
1 Mark for
Hydraulic actuators are majorly used for a systems which require very large force, but not
Advantages
very restrictive on positioning and accuracy.
Advantages of hydraulic actuators:
1. They can move moderate to heavy loads.
2. They are more efficient and deliver better performance than others. 1 Mark for
3. Power to weight ratio of these actuators is high. Disadvantag
es
Disadvantages:-
[1] Leakage of fluid
[2] hydraulic fluid is flammable
[3] lags in the control of the system due to the transmission lines and oil viscosity changes
from temperature

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